Cushioning product and method

ABSTRACT

A cushioning product comprises an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along the fold lines in an accordion-like fashion, and a storage and dispensing device which stores the folded sheet compressed and from which the sheet is dispensed for use. The sheet can be 8″ to 12″ wide. The fold lines can be 1″ apart. The sheet can have transverse perforations. The transverse perforations can be 16″ apart. The sheet has lateral edge portions and the lateral edge portions can be folded over onto the balance of the sheet. The folded over lateral edge portions can be 2″ wide, or the folded over lateral edge portions can substantially meet. In the latter case the folded over lateral edge portions can have a small space between them. The paper stock can be Kraft paper, recycled paper, or a combination of Kraft paper and recycled paper. The storage and dispensing device can be configured to store the folded compressed sheet linearly, for example can be a box magazine. The storage and dispensing device can also be configured to store the folded compressed sheet spirally, for example can be a drum magazine.

FIELD OF THE INVENTION

[0001] This invention relates generally to cushioning products, and more specifically to a cushioning product produced offsite for onsite delivery and use.

BACKGROUND OF THE INVENTION

[0002] In the process of shipping an item from one location to another, a protective packaging material is typically placed in the shipping carton or box, to fill any voids and/or to cushion the item during the shipping process. Examples of protective packaging materials are foam “peanuts,” air filled plastic “pillows,” and paper sheet material “converted” into cushioning pads.

[0003] In the case of air pillows and paper pads the current practice is for a shipper, for example manufacturer or distributor of goods, to either lease or purchase a machine for onsite production of the air pillows or paper pads. Typically a shipper must be of a fairly substantial size and means in order to justify the cost of an onsite machine.

[0004] Due to a changing economy there has been an increase in the number of shippers that ship only one or two items per box, as well as an increase in the number of small packages shipped. Consequently there has been an increase in the so-called “small user” market segment for economical protective packaging materials which do not require the expenditure of large capital sums for onsite cushioning product production machines.

SUMMARY OF THE INVENTION

[0005] In accordance with the principles of the present invention, a cushioning product comprises an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along the fold lines in an accordion-like fashion, and a storage and dispensing device which stores the folded sheet compressed and from which the sheet is dispensed for use as a cushioning product.

[0006] The sheet can be 8″ to 12″ wide. The fold lines can be 1″ apart. The sheet can have transverse perforations. The transverse perforations can be 16″ apart.

[0007] The sheet has lateral edge portions and the lateral edge portions can be folded over onto the balance of the sheet. The folded over lateral edge portions can be 2″ wide, or the folded over lateral edge portions can substantially meet. In the latter case the folded over lateral edge portions can have a small space between them.

[0008] The paper stock can be Kraft paper, recycled paper, or a combination of Kraft paper and recycled paper.

[0009] The storage and dispensing device can be configured to store the folded compressed sheet linearly, for example can be a box magazine. The storage and dispensing device can also be configured to store the folded compressed sheet spirally, for example can be a drum magazine.

[0010] In another aspect the invention is a method of packing an item in a box comprising providing the item, providing the box, providing an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along the fold lines in an accordion-like fashion, the folded sheet being provided stored compressed by a storage and dispensing device from which the sheet is dispensed for use, dispensing a selected length of the folded paper stock sheet, separating the selected length of folded paper stock sheet from that remaining in the storage and dispensing device, placing the item in the box and placing the selected length of folded paper stock sheet between the item and a wall of the box.

[0011] In yet another aspect, the invention is a method of packing an item in a box comprising providing the item, providing the box, providing an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along the fold lines in an accordion-like fashion, the folded sheet being provided stored compressed by a storage and dispensing device from which the sheet is dispensed for use, dispensing a selected length of the folded paper stock sheet, separating the selected length of folded paper stock sheet from that remaining in the storage and dispensing device, wrapping the item with a selected length of folded paper stock sheet and placing the wrapped item in the box.

[0012] In still another aspect, the invention is a method of packing an item in a box comprising providing the item, providing the box, providing an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along the fold lines in an accordion-like fashion, the folded sheet being provided stored compressed by a storage and dispensing device from which the sheet is dispensed for use, dispensing a first selected length of the folded paper stock sheet, separating the first selected length of folded paper stock sheet from that remaining in the storage and dispensing device, wrapping the item with the first selected length of folded paper stock sheet, placing the wrapped item in the box, dispensing a second selected length of the folded paper stock sheet, separating the second selected length of folded paper stock sheet from that remaining in the storage and dispensing device and placing the second selected length of folded paper stock sheet between the wrapped item and a wall of the box.

[0013] The major advantage of the invention is that it provides the so-called small user of protective packaging with an economical paper cushioning pad which is produced and packaged offsite for use onsite by the small user, thereby obviating the need for the small user to invest in cushioning product production machinery.

[0014] These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a top view of the cushioning product of the present invention;

[0016]FIG. 2 is a side view of the cushioning product of FIG. 1;

[0017]FIG. 3 is an end view of an elongated sheet of paper stock having lateral edge portions folded over onto the balance of the sheet and from which the cushioning product of FIGS. 1 and 2 can be produced;

[0018]FIG. 4 is a view similar to FIG. 3 but with the folded over lateral edge portions substantially meeting;

[0019]FIG. 5 is a side view of the cushioning product of FIGS. 1 and 2 stored compressed linearly in a box magazine; and

[0020]FIG. 6 is a side view of the cushioning product of FIGS. 1 and 2 stored compressed spirally in a drum magazine.

DETAILED DESCRIPTION OF THE INVENTION

[0021] Referring first to FIG. 1, there is illustrated a cushioning product 10 according to the principles of the present invention. Cushioning product 10 is produced from an elongated sheet 12 of paper stock having transverse fold lines 14 and being alternatingly folded along the fold lines 14 in an accordion-like or fan-folded fashion. Sheet 12 can be Kraft paper, recycled paper or a combination of Kraft paper and recycled paper. Sheet 12 can be 8″ to 12″ wide, and the fold lines 14 can be about 1″ apart. Sheet 12 can include perforations 16, which perforations can be about 16″ apart. Thus, a 16″ length of 1″ fan-folded paper stock sheet 12 forms an accordion-like pad about 12″ long by 12″ wide by about {fraction (23/32)}″ thick, a size especially suited to the small user.

[0022] Referring now to FIGS. 3 and 4, sheet 12, preferably a single ply sheet, can be reinforced by folding over the lateral edge portions 20 over onto the balance of the sheet 12. Fold over lateral edge portions 20 can be 2″ wide, for example, as shown in FIG. 3. Or, as shown in FIG. 4, the folded over lateral edge portions 20 can substantially meet, with only a small space 22 being left therebetween.

[0023]FIG. 5 illustrates one type of storage and dispensing device 30 in which the cushioning product 10 can be stored and from which the cushioning product 10 can be dispensed. Storage and dispensing device 30 is in the form of a box magazine in which the folded sheet 12, from which the cushioning product 10 is formed, is stored compressed linearly. Box magazine 30 can be fabricated of paper and is about 8¼″ wide by 11″ long by 1⅛″ thick for storing the 8″ wide sheet 12. The capacity of such a size of box magazine 30 is 140 linear feet of sheet 12 and 100 linear feet of cushioning pad 10. A box magazine storage and dispensing device (not shown) could be fabricated to hold, for example, 12 such box magazines 30, which would provide a total capacity of 1200 linear feet of 8″ wide cushioning pad 10. Alternatively, storage and dispensing device 30 could be fabricated from ABS plastic as on open top tray (not shown), with the trays being configured to stack one upon another.

[0024]FIG. 6 illustrates another type of storage and dispensing device 40 in which the cushioning product 10 can be stored and from which the cushioning product 10 can be dispensed. Storage and dispensing device 40 is in the form of a drum magazine in which the folded sheet 12, from which the cushioning product 10 is formed, is stored compressed spirally. Drum magazine 40 includes a central spine or tube 42 about 2′ in diameter about which are spiraled walls 44 which are spaced about 1″ apart. Alternatively, storage and dispensing device 40 could comprise simply the spine or tube 42 with the folded sheet 12 simply spiraled around the tube 42. Drum magazine 40 can be 12″ wide by about 16″ in diameter for storing the 12″ wide sheet 12. The capacity of such a size of drum magazine 40 (or of fan-folded paper sheet 12 simply wrapped around tube 42) is 2,586 linear feet of sheet 12 and 1,836 linear feet of 12″ wide cushioning pad 10.

[0025] In use, a length of the folded paper stock sheet 12 is dispensed from either box magazine 30 or drum magazine 40 (or simply from tube 42). The length of the folded paper stock sheet 12 is then separated from that remaining in the storage and dispensing device 30 or 40, and the cushioning product 12 formed by the expanding fan-folded or accordion-folded sheet 12 is then placed between the item and a wall of the box in which the item is to be shipped, or is used to wrap the item and the wrapped item is placed in the box. In addition or alternatively, the item can be wrapped with one length of cushioning product 10, placed in the box and a second length of cushioning product 10 can be placed between the wrapped item and a wall of the box.

[0026] Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the present invention which will result in an improved cushioning product and method, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents. 

What is claimed is:
 1. A cushioning product comprising: an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along said fold lines in an accordion-like fashion; and a storage and dispensing device which stores said folded sheet compressed and from which said sheet is dispensed for use as a cushioning product.
 2. The cushioning product of claim 1 wherein said sheet is 8 to 12 inches wide.
 3. The cushioning product of claim 2 wherein said fold lines are 1 inch apart.
 4. The cushioning product of claim 3 wherein said sheet has transverse perforations.
 5. The cushioning product of claim 4 wherein said transverse perforations are 16 inches apart.
 6. The cushioning product of claim 1 wherein said sheet has lateral edge portions and said lateral edge portions are folded over onto the balance of said sheet.
 7. The cushioning product of claim 6 wherein said folded over lateral edge portions are 2 inches wide.
 8. The cushioning product of claim 6 wherein said folded over lateral edge portions substantially meet.
 9. The cushioning product of claim 8 wherein said folded over lateral edge portions have a small space therebetween.
 10. The cushioning product of claim 1 wherein said paper stock is Kraft paper.
 11. The cushioning product of claim 1 wherein said paper stock is recycled paper.
 12. The cushioning product of claim 1 wherein said paper stock is a combination of Kraft paper and recycled paper.
 13. The cushioning product of claim 1 wherein said storage and dispensing device is configured to store said folded compressed sheet linearly.
 14. The cushioning product of claim 13 wherein said storage and dispensing device is a box magazine.
 15. The cushioning product of claim 1 wherein said storage and dispensing device is configured to store said folded compressed sheet spirally.
 16. The cushioning product of claim 15 wherein said storage and dispensing device is a drum magazine.
 17. A method of packing an item in a box comprising: providing the item; providing the box; providing an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along said fold lines in an accordion-like fashion, said folded sheet being provided stored compressed by a storage and dispensing device from which said sheet is dispensed for use; dispensing a selected length of said folded paper stock sheet; separating said selected length of folded paper stock sheet from that remaining in said storage and dispensing device; placing said item in said box; and placing said selected length of folded paper stock sheet between said item and a wall of said box.
 18. The method of claim 17 wherein said sheet is 8 to 12 inches wide.
 19. The method of claim 18 wherein said fold lines are 1 inch apart.
 20. The method of claim 19 wherein said sheet has transverse perforations.
 21. The method of claim 20 wherein said transverse perforations are 16 inches apart.
 22. The method of claim 17 wherein said sheet has lateral edge portions and said lateral edge portions are folded over onto the balance of said sheet.
 23. The method of claim cushioning product of claim 22 wherein said folded over lateral edge portions are 2 inches wide.
 24. The method of claim 22 wherein said folded over lateral edge portions substantially meet.
 25. The method of claim 24 wherein said folded over lateral edge portions have a small space therebetween.
 26. The method of claim 17 wherein said paper stock is Kraft paper.
 27. The method of claim 17 wherein said paper stock is recycled paper.
 28. The method of claim 17 wherein said paper stock is a combination of Kraft paper and recycled paper.
 29. The method of claim 17 wherein said storage and dispensing device is configured to store said folded compressed sheet linearly.
 30. The method of claim 29 wherein said storage and dispensing device is a box magazine.
 31. The method of claim 17 wherein said storage and dispensing device is configured to store said folded compressed sheet spirally.
 32. The method of claim 31 wherein said storage and dispensing device is a drum magazine.
 33. A method of packing an item in a box comprising: providing the item; providing the box; providing an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along said fold lines in an accordion-like fashion, said folded sheet being provided stored compressed by a storage and dispensing device from which said sheet is dispensed for use; dispensing a selected length of said folded paper stock sheet; separating said selected length of folded paper stock sheet from that remaining in said storage and dispensing device; wrapping said item with said selected length of folded paper stock sheet; and placing said wrapped item in said box.
 34. The method of claim 33 wherein said sheet is 8 to 12 inches wide.
 35. The method of claim 34 wherein said fold lines are 1 inch apart.
 36. The method of claim 35 wherein said sheet has transverse perforations.
 37. The method of claim 36 wherein said transverse perforations are 16 inches apart.
 38. The method of claim 33 wherein said sheet has lateral edge portions and said lateral edge portions are folded over onto the balance of said sheet.
 39. The method of claim cushioning product of claim 38 wherein said folded over lateral edge portions are 2 inches wide.
 40. The method of claim 38 wherein said folded over lateral edge portions substantially meet.
 41. The method of claim 40 wherein said folded over lateral edge portions have a small space therebetween.
 42. The method of claim 33 wherein said paper stock is Kraft paper.
 43. The method of claim 33 wherein said paper stock is recycled paper.
 44. The method of claim 33 wherein said paper stock is a combination of Kraft paper and recycled paper.
 45. The method of claim 33 wherein said storage and dispensing device is configured to store said folded compressed sheet linearly.
 46. The method of claim 45 wherein said storage and dispensing device is a box magazine.
 47. The method of claim 33 wherein said storage and dispensing device is configured to store said folded compressed sheet spirally.
 48. The method of claim 47 wherein said storage and dispensing device is a drum magazine.
 49. A method of packing an item in a box comprising: providing the item; providing the box; providing an elongated sheet of paper stock having transverse fold lines and being alternatingly folded along said fold lines in an accordion-like fashion, said folded sheet being provided stored compressed by a storage and dispensing device from which said sheet is dispensed for use; dispensing a first selected length of said folded paper stock sheet; separating said first selected length of folded paper stock sheet from that remaining in said storage and dispensing device; wrapping said item with said first selected length of folded paper stock sheet; placing said wrapped item in said box; dispensing a second selected length of said folded paper stock sheet; separating said second selected length of folded paper stock sheet from that remaining in said storage and dispensing device; and placing said second selected length of folded paper stock sheet between said wrapped item and a wall of said box.
 50. The method of claim 49 wherein said sheet is 8 to 12 inches wide.
 51. The method of claim 50 wherein said fold lines are 1 inch apart.
 52. The method of claim 51 wherein said sheet has transverse perforations.
 53. The method of claim 52 wherein said transverse perforations are 16 inches apart.
 54. The method of claim 49 wherein said sheet has lateral edge portions and said lateral edge portions are folded over onto the balance of said sheet.
 55. The method of claim cushioning product of claim 54 wherein said folded over lateral edge portions are 2 inches wide.
 56. The method of claim 54 wherein said folded over lateral edge portions substantially meet.
 57. The method of claim 56 wherein said folded over lateral edge portions have a small space therebetween.
 58. The method of claim 49 wherein said paper stock is Kraft paper.
 59. The method of claim 49 wherein said paper stock is recycled paper.
 60. The method of claim 49 wherein said paper stock is a combination of Kraft paper and recycled paper.
 61. The method of claim 49 wherein said storage and dispensing device is configured to store said folded compressed sheet linearly.
 62. The method of claim 61 wherein said storage and dispensing device is a box magazine.
 63. The method of claim 49 wherein said storage and dispensing device is configured to store said folded compressed sheet spirally.
 64. The method of claim 63 wherein said storage and dispensing device is a drum magazine. 